Dust and debris collection system for woodworking routers

ABSTRACT

A dust and debris collection system for use with woodworking routers, including a baffle, a dust collection hood, and a brush. The baffle includes a top surface, where the top surface is configured to deflect cooling air generated by a woodworking router out and away from the woodworking router in order to allow the woodworking router adequate cooling and efficient dust collection. The dust collection hood is located adjacent to the baffle and includes a sloped wall that is aerodynamically shaped to remove dust and debris and includes a central bit hole configured to accept a bit. The brush has a series of bristles extending from the dust collection hood. The brush and its bristles contain dust and debris.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application,Ser. No. 62/387,872, filed on Jan. 6, 2016, which is hereby incorporatedby reference for all purposes.

BACKGROUND

The present disclosure relates generally to woodworking routers. Inparticular, dust and debris collection systems that redirect cooling airflow while managing dust and debris are described for use withwoodworking routers.

Woodworking routers are tools used to remove material from a hardworkpiece, the workpiece typically being made of wood, plastic, ormetal. To remove the material, the woodworking router uses a bit spun athigh-speeds in order to cut out the material. As the bit cuts out thematerial, it cuts away at the material creating bits of debris includingshavings, chips, and dust. These bits of debris can become a nuisanceand a safety hazard. Because of the high rate of speed with which therouter bit spins, the shavings, chips and dust can be spread aconsiderable distance in all directions from the router bit, creating alarge mess for a user to clean. In addition, commonly available routersuse a fan to cool the motor windings and blow the shavings, chips anddust away from the router motor and workpiece. The fan further spreadsthe debris, complicating collection and containment of the shavings,chips, and dust.

In addition to being a nuisance, the debris may also be a health hazardto the user of a router or observers in the area. For example, somematerials may produce carcinogenic dust. This may be a potentiallydeadly hazard if the carcinogenic dust is inhaled. Additionally, debrismay be thrown with a high velocity capable of causing injury to a useror observer. To protect themselves from personal injury while using arouter, a user or observer will generally wear protective clothing,including a mask for protection against the dust, and goggles or glassesfor protection against flying debris.

Known dust and debris collection systems implemented with woodworkingrouters are not entirely satisfactory for the range of applications inwhich they are employed. For example, current dust and debris collectionsystems may only surround a portion of the bit or router area to allowthe bit to spin freely and move around the workpiece. However, thesedust and debris collection systems leave part of the bit and work areaexposed. This allows debris and dust to escape the collection systemthrough the exposed area. In addition, the fan used to cool the motorand remove material from the bit area further spreads the debris awayfrom the work area and additionally the current collection systems.

Thus, there exists a need for a dust collection system that prevents therouter motor cooling air from blowing dust and debris away from therouter. Additionally, there is a need for a dust collection system thatacts as an engineered control to reduce risk from flying dust and debrishazards created by the router.

SUMMARY

The present disclosure is directed to a dust and debris collectionsystem for use with woodworking routers. The collection system has abaffle, a dust collection hood, and a brush. The baffle includes a topsurface, where the top surface is configured to deflect cooling airgenerated by a woodworking router out and away from the woodworkingrouter in order to allow the woodworking router adequate cooling. Thedust collection hood is located adjacent to the baffle. The dustcollection hood includes a sloped wall that is aerodynamically shaped toremove dust and debris and a central bit hole configured to accept abit. The brush has a series of bristles extending from the dustcollection hood. The brush and its bristles contain dust and debris.

The collection system is capable of moving freely with a woodworkingrouter to collect and remove dust and debris. The collection system isalso interchangeable with multiple woodworking routers. In order to workwith a woodworking router, the collection system includes an attachmentmechanism located around a perimeter of the baffle. The attachmentmechanism may include at least one tab with at least one hole, the tabextending from the perimeter of the baffle. A screw may be placedthrough the hole in the tab to attach the collection system to awoodworking router mount.

Furthermore, the top surface of the baffle is a surface of the slopedwall of the dust collection hood. As the baffle and the dust collectionhood are adjacent to each other, they both utilize the sloped wall. Thesloped wall is a conically shaped wall that contributes to theaerodynamics of the collection system. Located near the center of theconical sloped wall is an interior flange. The interior flange iscylindrically shaped and configured to surround the bit of thewoodworking router. Further, the interior flange and the sloped wallinclude a notch or cutout that align with one another. The notch orcutout allows access to a router motor lock of a woodworking routerwhile the collection system is attached to the woodworking router mount.With this access, a locking pin may be accessed and the bit interchangedwithout removing the collection system from the woodworking router.

The dust collection hood also includes a hood wall that surrounds aperimeter of the dust collection hood. Extending from the hood wall is adischarge port. The discharge port allows a vacuum system to attach tothe collection system to allow the vacuum system to remove dust anddebris. The discharge port may also include a screwdriver hole to allowa screwdriver to be inserted in order to access an attachment screw, ifnecessary. In order to keep the vacuum hose attached to the dischargeport, there is at least one ridge on the discharge port. The ridgeincreases the friction or provides a compressive force that assists tohold the vacuum hose on to or inside the discharge port.

Turning to the brush, it includes a series of bristles that areflexible. The bristles may be long enough to contact a workpiece. Thesebristles attach to a detachable band. The detachable band may attach tothe hood wall and surround a perimeter of the dust collection hood. Bysurrounding the dust collection hood, the bristles create a wall that isair permeable. With an air permeable wall, the vacuum can create thesuction and air flow necessary to remove dust and debris.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a first example of a dust and debriscollection system as used with a woodworking router, and where a vacuumis attached to the dust and debris collection system.

FIG. 2 is a perspective view of the dust and debris collection systemshown in FIG. 1 detached from the woodworking router and the vacuumsystem.

FIG. 3 is a top view of the dust and debris collection system shown inFIG. 1 depicting the overall shape of the collection system as well as abaffle for deflecting cooling air from the woodworking router.

FIG. 4 is a side view of the dust and debris collection system shown inFIG. 1 depicting an opening to access a router shaft locking mechanism.

FIG. 5 is a cross-sectional view of the dust and debris collectionsystem shown in FIG. 1 depicting the internal shape and structure of theinternal baffle and dust collection hood.

FIG. 6 is a bottom view of the dust and debris collection system shownin FIG. 1 depicting the internal, aerodynamic structure of a dustcollection hood.

DETAILED DESCRIPTION

The disclosed dust and debris collection system will become betterunderstood through review of the following detailed description inconjunction with the figures. The detailed description and figuresprovide merely examples of the various inventions described herein.Those skilled in the art will understand that the disclosed examples maybe varied, modified, and altered without departing from the scope of theinventions described herein. Many variations are contemplated fordifferent applications and design considerations; however, for the sakeof brevity, each and every contemplated variation is not individuallydescribed in the following detailed description.

Throughout the following detailed description, examples of various dustand debris collection systems are provided. Related features in theexamples may be identical, similar, or dissimilar in different examples.For the sake of brevity, related features will not be redundantlyexplained in each example. Instead, the use of related feature nameswill cue the reader that the feature with a related feature name may besimilar to the related feature in an example explained previously.Features specific to a given example will be described in thatparticular example. The reader should understand that a given featureneed not be the same or similar to the specific portrayal of a relatedfeature in any given figure or example.

With reference to FIGS. 1-6, a first example of a dust and debriscollection system, collection system 100, will now be described. Withreference to FIG. 1, collection system 100 includes a baffle 102, a dustcollection hood 104, and a brush 106. Collection system 100 fits with awoodworking router 107 and attaches to a woodworking router mount 108and a vacuum 110 to efficiently and effectively collect and control dustand debris created by the woodworking router 102.

Collection system 100 addresses many of the shortcomings existing withcurrent dust and debris collection systems. For example, collectionsystem contributes to a much safer environment, virtually free of dustand debris produced by the woodworking router 107. As bit 112 is spun ata high rate of speed and cuts at a material to remove portions of thematerial, it creates shavings, chips, and dust. Collection system 100encompasses the bit and surrounding area with the collection hood 104and brush 106, and any dust or debris created is contained and suctionedinto the vacuum 110 attached to collection system 100. By containing andvacuuming the dust and debris, there is a reduced risk of injury byflying chips and shavings, and it is less likely that dust will beinhaled by a user or observer.

Collection system 100 also addresses the shortcoming of adequate airflowfor cooling the woodworking router 107 and still containing dust anddebris. Collection system 100 includes a baffle 102 that redirectscooling air produced by the woodworking router 107 in a direction awayfrom the bit and the material. The redirected air is still adequate tocool the woodworking router, and dust and debris created by the bit isnot spread because the work area is protected by the baffle 102. Baffle102 additionally does not restrict access to the bit 112, allowing it tobe interchanged without removal of collection system 100. Baffle 102includes a small hole, notch, or void to allow the insertion of a fingeror tool so the bit may be easily interchanged.

Collection system 100 may be made from any suitable material, includingplastic. The plastic may be thermoformed or injection molded to make theshape of collection system 100. The brush 106 may also be made of anysuitable material that is flexible and air permeable. In the followingexample embodiments of the invention, the brush 106 may be made ofsynthetic bristles, such as nylon, or natural bristles, such as hair.

Turning to FIG. 2, collection system includes a baffle 102, dustcollection hood 104, and brush 106. The baffle 102 is located adjacentto the dust collection hood 104 such that the baffle 102 sits on top ordirectly above and in line with the dust collection hood 104. The brush106 extends downward from the dust collection hood 104 and is attachedto and around a perimeter of the dust collection hood 104.

As can be seen in FIG. 2, and better exemplified in FIG. 3, the baffle102 may be located at a top end of the collection system 100. The baffle102 may be configured to redirect cooling air from the woodworkingrouter out and away from the bit and workpiece. The baffle 102, as shownin this example embodiment, may be substantially circular in shape, andmay include a top surface 120 which is sized to cover or be placed nearan end of a woodworking router to deflect the cooling air. The baffle102 may include around its perimeter an attachment mechanism in order toattach to a woodworking router at a router holding mount or jig. In thisexample embodiment, the baffle 102 includes at least one tab 122extending from the baffle 102. The tab 122 includes a tab hole 124 thatextends completely through the tab 122. The tab 122 and tab hole 124 aresized and configured to accept a screw 126 in order to attach to thewoodworking router mount 108, as exemplified in FIG. 1. In alternateembodiments of the invention, the tab 122 may include a snap, clamp,adhesive, or other attachment mechanism in order to attach to thewoodworking router at various router holding mounts or jigs.

Referring to FIG. 3, the tab 122 and tab hole 124 extending through thetab 122 allow for collection system 100 to be attached to commonwoodworking routers, mounts, and jigs using a common screw. Likewise,the tab 122 and tab hole 124 allow for collection system 100 to beremoved from a woodworking router and transferred to another woodworkingrouter, allowing for the interchangeability of collection system 100with multiple different jigs, routers, or machines. Because collectionsystem 100 attaches to the woodworking router mount 108, as exemplifiedin FIG. 1, collection system 100 moves freely with the woodworkingrouter 107, allowing for better maintenance, collection, and removal ofdust and debris.

As seen further in FIG. 2 and FIG. 3, the baffle 102 may also include abarrier to separate the bit from the redirected cooling air. In thisexample embodiment, the baffle 102 may include an interior flange 128.The interior flange 128 may be a substantially cylindrical wallpositioned near a center area of the baffle 102. The interior flange 128surrounds the bit attached to the woodworking router 107 and isconfigured to redirect the cooling air away from the bit and theworkpiece. The interior flange 128 may include a notch 130. Notch 130may be a small cutout or void in the interior flange 128 to allow accessto the bit while the collection system 100 is attached and in place onthe woodworking router mount 108. In alternate embodiments of theinvention, the interior flange 128 may not include a notch or void, andthe interior flange 128 may be one uninterrupted piece.

As seen in FIG. 4, the baffle 102 may be shaped to efficiently andeffectively redirect the cooling air from the woodworking router 107. Inthis example embodiment, baffle 102 includes a sloped wall 132 on itsinterior that is substantially conical in shape. The baffle 102 alsoincludes a sidewall 134 around the perimeter of the sloped wall 132 thatextends from the sloped wall 132 outward toward the woodworking routerwhen collection system 100 is attached. The interior flange 128 extendsfrom a center portion of the sloped wall 132 outward toward thewoodworking router when collection system 100 is attached. The slopedwall 132, sidewall 134, and interior flange 128 are configured toaerodynamically redirect any cooling air from the woodworking routerthat may be directed toward the bit and workpiece away from the bit andworkpiece.

Referring back to FIG. 2, the sloped wall 132 and sidewall 134 may alsoinclude a cutout 136 which may be a notch, void, or other opening in thebaffle 102. The cutout 136 is configured to efficiently and effectivelyredirect cooling air produced by the woodworking router. The cutout 136of the sloped wall 132 and sidewall 134 allow for the cooling air torapidly be moved from the woodworking router to the surrounding areaaway from the woodworking router and workpiece. In alternateembodiments, there is no cutout. In these alternate embodiments, thesloped wall 132 and sidewall 134 redirect the cooling air outward awayfrom the woodworking router, directing the air in a directionperpendicular to the woodworking router. In these examples, the coolingair may also be directed away from the woodworking router through anyspacing or gap between the baffle and the woodworking router.

Referring to FIG. 3 and FIG. 4, the baffle 102 of collection system 100may be configured to allow for access to the bit and the lock ormechanism to interchange the bit. In this example embodiment of theinvention, the notch 130 in the interior flange 128 and the cutout 136in the sloped wall 132 and sidewall 134 are configured to allow a userto access and interchange the bit on the woodworking router 107. Formany common woodworking routers, in order to change a bit, a user mustuse a finger or tool to loosen a locking nut or compress a button on thewoodworking router adjacent to the bit. The notch 130 and cutout 136 areconfigured to allow a user to have access to the locking nut or buttonon the woodworking router adjacent to the bit. In this exampleembodiment of the invention, collection system 100 does not need to beremoved from the woodworking router mount prior to interchanging bits.Instead, a tool or finger may be inserted into the notch 130 and cutout136 in order to access the woodworking router 107 and change the bitwhile collection system 100 is still attached to the woodworking routermount 108.

Turning now to FIG. 5, collection system 100 may include a dustcollection hood 104. The dust collection hood 104 may be locatedadjacent to the baffle 102 and configured to contain and collect dustand debris created by the bit removing material from a workpiece. As canbe seen in FIG. 6, the dust collection hood 104, in this exampleembodiment, may be substantially the same size and shape as the baffle102. The dust collection hood 104 may include a central bit hole 138where the bit 112 from the woodworking router 107 may extend throughcollection system 100 in order to reach the workpiece.

As exemplified in FIG. 5, the dust collection hood 104 may be shaped toefficiently and effectively collect, contain, and remove any dust anddebris created by the bit of woodworking router 107. In this exampleembodiment, dust collection hood 104 includes the sloped wall 132 ofbaffle 102 on its interior that is substantially conical in shape. Asseen in FIG. 4 and FIG. 5, the dust collection hood 104 may also includea hood wall 140 around the perimeter of the sloped wall 132. The hoodwall 140 may extend from an edge of the sloped wall 132 toward theworkpiece, away from the woodworking router. The hood wall 140 andsloped wall 132 are configured to effectively collect, contain, andremove any dust or debris created by the bit.

As can be seen in FIG. 5, and in reference to FIG. 6, the dustcollection hood 104 may include a discharge port 142. The discharge port142 is configured to connect collection system 100 to a vacuum in orderto effectively and efficiently collect, contain, and remove dust anddebris. In this example embodiment, the discharge port 142 may connectto the hood wall 140 with curved connection walls 144 that areconfigured to aerodynamically remove dust and debris from the dustcollection hood 104.

As can further be seen in FIG. 5, the discharge port 142 may include avacuum attachment end 146 configured to connect to a vacuum. In thisexample embodiment, the vacuum attachment end 146 is circular orcylindrical in shape, and is sized to be inserted into a vacuum hose orhose adaptor. The vacuum attachment end 146 may also include at leastone ridge 148 extending out from an outer edge or side of the dischargeport 142. The ridge 148 may be configured to provide friction or asqueezing, compressive force in order to secure a vacuum to thedischarge port 142. In an alternate embodiment, the vacuum attachmentend 146 may be configured and sized to fit over a vacuum hose. In thisalternative embodiment, the at least one ridge 148 may be on an interioredge or side of the discharge port 142 and configured to providefriction or a compressive force on a vacuum hose that is inserted intothe vacuum attachment end 146.

As seen in FIG. 6, the discharge port 142 may include a hole or way toaccess the attachment mechanism that attaches collection system 100 to awoodworking router mount 108. In this example embodiment, the dischargeport 142 may include a screwdriver hole 150 in order to access the tabhole 124 on the tab 122. A screwdriver may be inserted into thescrewdriver hole 150 in order to access and turn a screw that has beeninserted through the tab hole 124. In alternate embodiments of theinvention, the tab 122 may be located in a position away from thedischarge port 142 such that a screwdriver hole is unnecessary to accessthe tab 122 and attachment mechanism.

Turning now to FIG. 5, and as exemplified in FIG. 6, collection system100 may include a brush 106. The brush 106 may be located adjacent tothe dust collection hood 104 and configured to contain and collect dustand debris created by the bit removing material from a workpiece whilemaintain airflow through the dust collection hood 104 in order to removethe dust and debris. The brush 106 may assist to direct dust and debristoward the dust collection hood 104 which may then aerodynamicallyremove the dust and debris through the discharge port 142.

As seen in FIG. 5, the brush 106 may be a series of long, flexiblebristles 152 extending from and attached to a detachable band 154. Thedetachable band 154 may be a steel band that fits or attaches to aperimeter of the dust collection hood 104. In order to attach and detachfrom the dust collection hood, the detachable band 154 may include aslit 156 as shown in FIG. 4, where the slit allows the detachable bandto flex and bend enough to fit into a groove 158 on the dust collectionhood 104. The brush 106 may be removed and replaced for router bitchanges and maintenance. Turning back to FIG. 5, the bristles 152 extendtoward the workpiece and may be long enough to touch the workpiece whilethe bit removes material from the workpiece. The bristles 152 create anair permeable wall suitable to allow air to flow through. In alternateembodiments of the invention, the bristles 152 do not extend far enoughto touch the workpiece while the bit removes material.

Referring to FIGS. 1-6, the dust collection hood 104 and the brush 106may be configured to contain, collect, and remove dust and debris andnot allow the dust and debris to escape into a surrounding space. Inthis example embodiment, to contain and remove dust and debris, a vacuum110 may be attached to the vacuum attachment end 146 of the dischargeport 142. When the vacuum 110 is turned on, it may create a suction orlow pressure force within the discharge port 142 and the dust collectionhood 104. The suction or low pressure force will draw in air from ahigher pressure area outside the dust collection hood 104. The drawn inair may be drawn in through or around the bristles 152 of the brush 106,or through an opening at the end of the brush. Because of theaerodynamic shape of the dust collection hood 104, the drawn in air willbe funneled into and through the dust collection hood 104 and thedischarge port 142. Any dust or debris caught in this flow of air willbe removed. Because the bit removes material from the workpiece withinthe airflow area adjacent to the brush 106 and dust collection hood 104,the removed material will be suctioned away from the workpiece and intothe vacuum, effectively containing and removing the dust and debris.

The disclosure above encompasses multiple distinct inventions withindependent utility. While each of these inventions has been disclosedin a particular form, the specific embodiments disclosed and illustratedabove are not to be considered in a limiting sense as numerousvariations are possible. The subject matter of the inventions includesall novel and non-obvious combinations and subcombinations of thevarious elements, features, functions and/or properties disclosed aboveand inherent to those skilled in the art pertaining to such inventions.Where the disclosure or subsequently filed claims recite “a” element, “afirst” element, or any such equivalent term, the disclosure or claimsshould be understood to incorporate one or more such elements, neitherrequiring nor excluding two or more such elements.

Applicant(s) reserves the right to submit claims directed tocombinations and subcombinations of the disclosed inventions that arebelieved to be novel and non-obvious. Inventions embodied in othercombinations and subcombinations of features, functions, elements and/orproperties may be claimed through amendment of those claims orpresentation of new claims in the present application or in a relatedapplication. Such amended or new claims, whether they are directed tothe same invention or a different invention and whether they aredifferent, broader, narrower or equal in scope to the original claims,are to be considered within the subject matter of the inventionsdescribed herein.

The invention claimed is:
 1. A dust and debris collection system adaptedfor use with a router with a bit for working on a workpiece, thecollection system comprising: a baffle comprising: a perimeter sidewall;and a sloped wall on the interior of said baffle, said sloped wallhaving a central bit hole formed therein adapted to accept the bit, saidsloped wall being sloped with respect to said perimeter sidewall andhaving a surface extending from said perimeter sidewall to the centralbit hole, said perimeter sidewall and said sloped wall having therein anopening, the opening being adapted to allow access to the router bit forchanging the bit without removal of the baffle, said surface beingadapted to redirect cooling air generated by the router away from therouter and the workpiece through the opening; a dust collection hoodlocated adjacent to the baffle, the dust collection hood comprised of:said sloped wall on the interior of said dust collection hood; aperimeter hoodwall connected to said sloped wall; and a discharge portconnected to said perimeter hoodwall and adapted to connect said dustcollection hood to a vacuum system to remove dust and debris from saiddust collection hood during use of the router; and a brush having aseries of bristles extending from the dust collection hood andconfigured to contain dust and debris.
 2. The collection system of claim1, further comprising a router, and wherein the collection systemattaches to said router and moves with said router to collect and removedust and debris.
 3. The collection system of claim 1, further comprisinga router and a router mount, said router being attached to said routermount, wherein the collection system is attached to said router mountand adapted to fit with the router, and wherein the collection systemmoves with the router and said router mount, and is adapted to allowremoval of dust and debris with the vacuum system.
 4. The collectionsystem of claim 3, further comprising: an attachment mechanism furtheradapting the collection system for attachment to said router mount. 5.The collection system of claim 4, wherein the attachment mechanismfurther comprises: at least one tab extending from the baffle, the atleast one tab having at least one hole extending completely through theat least one tab and sized and adapted to accept a screw to attach thecollection system to the router mount.
 6. The collection system of claim1, wherein said sloped wall is substantially conical shaped around andrelative to a central axis of rotation of the bit accepted by thecentral bit hole.
 7. The collection system of claim 6, said sloped wallof said baffle further comprising: an interior flange extending fromsaid sloped wall adjacent the central bit hole and adapted forsurrounding the bit as a barrier to redirect air away from the bit. 8.The collection system of claim 7, wherein said interior flange includesa void, and wherein the void of said interior flange and the opening ofsaid perimeter wall and said sloped wall align and are adapted to allowaccess to a router motor lock such that the bit may be interchangedwithout removing the collection system from the router.
 9. Thecollection system of claim 1, said discharge port comprising: at leastone ridge, the at least one ridge extending out from said discharge portand configured to provide friction or a squeezing compressive force tosecure said vacuum system to said discharge port.
 10. The collectionsystem of claim 1, wherein the series of bristles are flexible andadapted to contact a workpiece.
 11. The collection system of claim 1,further comprising a detachable band and a perimeter of said dustcollection hood, wherein the series of bristles of said brush attach tosaid detachable band, and wherein said detachable band attaches to saidperimeter of said dust collection hood.
 12. The collection system ofclaim 11, wherein the series of bristles create an air permeable wallcapable of allowing air to flow through or around the series ofbristles.